Lime-activated one-part geopolymer mortars from construction, demolition and industrial wastes

This work focused on the production of one-part geopolymer mortars from construction and demolition wastes (CDW) blended with steel slag. Previous related studies on geopolymer production from CDW utilized conventional two-part geopolymers comprised of highly alkaline activator solutions and CDW materials. Thus, the study's significance consists in producing high-strength (≥35 MPa) ambient-cured mortars from CDW with predominantly concrete waste by replacing conventional highly alkaline activator solutions with an environmentally-friendly alkaline activator, Ca(OH)2 powder. Four mortar mixtures were produced with CDW contents ranging from 50 to 65 % dry weight, varying the brick waste content from 3 to 18 %. The effect of elevated temperature (40 °C) curing was also considered. The results showed that 55 % CDW content had optimum performance across all parameters studied such as compressive and flexural strengths, setting time, as well as changes in nuclear magnetic resonance (NMR)-determined pore structure (porosity and mean pore size) and x-ray diffraction (XRD)-determined degree of crystallinity over time. It had 28-day compressive and flexural strengths of 42 and 5.8 MPa, respectively, and initial and final setting times of 25 and 50 min. The importance of sufficient brick waste content in the geopolymer mixtures for effective mechanical performance is highlighted. The inclusion of concrete waste in powder form reduced compressive strength under ambient curing but improved performance at 40 °C curing. It is concluded that sustainable structural mortars can be produced by ‘just adding water’ to an optimized CDW mixture with predominantly concrete waste blended with brick waste and slag and activated by powdered Ca(OH)2. •High-strength geopolymer mortars are produced with predominantly concrete wastes.•Ca(OH)2 was used as alkaline activator with 50–65 % CDW and varied brick contents.•The optimum mixture for all parameters incorporated 55 % CDW and 25 % slag contents.•Effect of including concrete waste as aggregate or powder is temperature dependent.•Sufficient brick waste content is required for effective performance over time.